CN101495286A

CN101495286A - Method for manufacturing crosslinked foam

Info

Publication number: CN101495286A
Application number: CNA2007800283530A
Authority: CN
Inventors: 朴章远
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-06-21
Filing date: 2007-06-21
Publication date: 2009-07-29
Anticipated expiration: 2027-06-21
Also published as: JP5143831B2; JP2009541088A; EP2029341A1; WO2007148929A1; EP2029341A4; US8506860B2; KR100689964B1; CN101495286B; US20100213630A1

Abstract

The present invention provides a method of manufacturing foam, including the steps of sealing a mold by providing a lower mold having an arbitrarily- shaped molding surface, and then sequentially placing a middle mold having at least one arbitrarily-shaped protrusion formed on one side thereof or both sides thereof and an upper mold having an arbitrarily-shaped molding surface on the lower mold; simultaneously forming an upper preform and a lower preform, which are prevented from foaming, by charging a foaming material in an inner molding space of each of the upper mold and the lower mold, which are divided by the middle mold; opening the mold and removing the middle mold from the mold; placing an interface material in grooves formed in the preform by the protrusion of the middle mold such that the upper preform and the lower preform are prevented from cross-linking with each other; and simultaneously cross-linking and foaming the upper preform and the lower preform by sealing the mold.

Description

Be used to make the method for crosslinked foams

Technical field

The present invention relates to a kind of foam manufacture method, relate more specifically to make the method for such foam, in this foam, can comprise the hollow structure of at least one arbitrary shape, perhaps can comprise the obturator of arbitrary shape owing to used intermediate mold.

Background technology

Usually, utilize the foam of various resin materials and additive manufacturing to have excellent material character.Therefore, it uses expansion rapidly.Traditionally, because foam is used for simple application, for example be used for packaging product, external vibration-absorbing etc., it has single group material character because of utilizing the homogenous material manufacturing.Yet, the function foam that recent demand different piece day by day has differing material properties or color.Therefore, the method for the such function foam of various manufacturings has been proposed.

Simultaneously, whether foam manufacture method basis is used mould and roughly is divided into pressure method and normal pressure method.In these methods, the pressure method that wherein uses mould is a kind of method of making foam according to the shape of in-mold molding face separately, in the method, expanded material is placed or is filled in the mould of the interior forming surface with arbitrary shape, under appropriate condition, the expanded material of placing or be filled in the sealed mold is heated pressurization, then the expanded material that is heated pressurization in the sealed mold is carried out fast decompression.

Make the field at froth pulp, pressure method is used very extensive, and this is because can repeat to obtain various froth pulps according to the shape of in-mold molding face.Yet, mainly be because pressure method is characterised in that the profile of utilizing the in-mold molding face to control final froth pulp, therefore this method extremely is difficult to form the part with certain material character in the froth pulp of intended shape, thereby this method can not obtain the function foam that different piece has differing material properties.

In order to address the above problem, most parties of association area have adopted a kind of like this foam manufacture method, wherein, each middle froth pulp with differing material properties or color at first is provided, then froth pulp in the middle of these is suitably cut and bonding one-tenth intended shape, thereby obtain the final froth pulp that different piece has differing material properties and color.Yet the shortcoming of this method is to have increased manufacturing cost owing to its complicate fabrication process, and owing to the cutting and the bonding process of froth pulp in the middle of manual the carrying out increased defect rate.

Summary of the invention

Technical problem

Therefore, make the present invention for addressing the above problem, and the object of the present invention is to provide a kind of method of making such foam in single foaming process, the different piece of this foam has the internal structure of different shape, and perhaps the different piece of foam has different material characters.

Another object of the present invention is to provide a kind of foam manufacture method, wherein, even the intermediate mold of different shape rather than the internal structure that a complete set of mould also can differently change foam only are provided.

Technical scheme

To achieve these goals, one aspect of the present invention provides a kind of foam manufacture method, this method may further comprise the steps, that is: the bed die with arbitrary shape forming surface is set, order is placed intermediate mold and the mold with arbitrary shape forming surface on this bed die then, thereby sealed mold, this intermediate mold has the projection of at least one arbitrary shape that forms on its one or both sides; Preventing under the condition of expanded material foaming prefabricated component and following prefabricated component on forming simultaneously by in the inside molding space of separating by described intermediate mold of described mold and described bed die, filling this expanded material; Open mould, and remove described intermediate mold from described mold and described bed die; In the groove that in described prefabricated component, forms by the projection of described intermediate mold, place boundary material, thereby prevent that described upward prefabricated component and described prefabricated component down are cross-linked with each other; And sealed mold and make described prefabricated component and the described prefabricated component down crosslinked foaming simultaneously of going up.

Another aspect of the present invention provides a kind of foam manufacture method, and this method may further comprise the steps, and places expanded material in the molding space of the inside of the bed die with arbitrary shape forming surface that is:; Intermediate mold is set, then this intermediate mold is placed on the described bed die, this intermediate mold has the projection of at least one arbitrary shape that forms on its one or both sides; On described intermediate mold, place expanded material, on this intermediate mold, place mold then with arbitrary shape forming surface, thus sealed mold; Under the condition of the expanded material that is separated by the described intermediate mold foaming of placing, described expanded material is formed respectively simultaneously go up prefabricated component and following prefabricated component preventing; Open mould and remove described intermediate mold from all the other moulds; In the groove that in described prefabricated component, forms by the projection of described intermediate mold, place boundary material, thereby prevent that described upward prefabricated component and described prefabricated component down are cross-linked with each other; And sealed mold and make described prefabricated component and the described prefabricated component down crosslinked foaming simultaneously of going up.

Described boundary material is characterised in that, this boundary material is placed in the described groove under its state that is coated by the prefabricated component of different arbitrary shapes, and this prefabricated component is formed by one or more materials of selecting among the material identical or different with constituting the described material of going up prefabricated component and/or described prefabricated component down and is prevented from foaming.

In addition, described boundary material is characterised in that, this boundary material is formed by one or more materials of selecting among fluent material and the solid material.

Described solid material is characterised in that the moulded product that it comprises arbitrary shape.

In addition, when described boundary material was solid material, described method also can be included in the step that the step that makes described prefabricated component crosslinked foaming removes described boundary material afterwards.

Described method is characterised in that described intermediate mold has a plurality of projections, and these projections are configured to interconnect.

Beneficial effect

As previously discussed, the invention has the advantages that and in single foaming process, to make such foam, this foam has the internal structure of different shape or has the inner molded foam of differing material properties, and comprises the moulded product of different shape in this foam.

Description of drawings

Fig. 1 to Fig. 4 is the schematic process diagram according to embodiment of the present invention;

Fig. 5 to Fig. 7 is the schematic process diagram of another embodiment according to the present invention;

Fig. 8 and Fig. 9 are the stereogram of expression according to intermediate mold of the present invention;

Figure 10 is the stereogram of expression according to moulded product of the present invention;

Figure 11 is the stereogram of expression according to boundary material of the present invention; And

Figure 12 to Figure 16 is the stereogram of expression various foams constructed in accordance.

Element explanation in the＜accompanying drawing 〉

10: foam 12: internal structure

14: molded foam 22: following prefabricated component

23: groove 24: interface

26: go up prefabricated component 30: boundary material

34: moulded product 120,130: bed die

140,150: intermediate mold 160,170: mold

142,144: projection 200: the expanded material injecting unit

The specific embodiment

Below, the preferred implementation that present invention will be described in detail with reference to the accompanying.Here, omit with irrelevant content of the technology of the present invention thought and prior art in the detailed description of conspicuous content.

Fig. 1 to Fig. 4 is the schematic process diagram of representing respectively according to the foam manufacture method of embodiment of the present invention.In Fig. 1 to Fig. 4, show the sectional structure chart of implementing inscape essential to the invention respectively.Foam manufacture method according to the present invention can comprise mould 100 is set, as shown in Figure 1; Form prefabricated component by filled with foaming material in mould 100, as shown in Figure 2; Remove intermediate mold and place boundary material, as shown in Figure 3; Prefabricated component is carried out crosslinked foaming, as shown in Figure 4.

Mould 100 can comprise bed die 120, mold 160 and intermediate mold 140.Can comprise corresponding forming surface in bed die 120 and the mold 160.The shape of forming surface is not done concrete restriction, and obviously can be according to the shape of the final froth pulp that will obtain and freely change over the profile shape.Intermediate mold 140 can be included in the projection that forms on its one or both sides.The concrete shape of projection is not limit, and can be formed by a plurality of projections, also can form by a plurality of projections are interconnected.In Fig. 1, show the intermediate mold 140 that on lower surface, is formed with three projections 142.In Fig. 8, show the concrete shape of intermediate mold 140.Simultaneously, in Fig. 9, show the structure that forms the intermediate mold 140 of projection 144 by a plurality of projections are interconnected thereon.The

Reference numeral

122 and 162 of Miao Shuing does not refer to corresponding expanded material injection-tube.

After mould 100 is set, by on bed die 120, placing intermediate mold 140 and mold 160 in proper order and sealed mold 100.Then, as shown in Figure 2, utilize in the space that forms between the forming surface of lower surface that corresponding outside expanded material injecting unit 200 is filled into expanded material injection the space that forms between the upper surface of the forming surface of mold 160 and intermediate mold 140 and intermediate mold 140 and bed die 120, thereby form last prefabricated component 26 and the following prefabricated component 22 that is prevented from foaming simultaneously.Expanded material used among the present invention is unrestricted, as long as it can obtain foam.

Under the state that is prevented from foaming, form after the

prefabricated component

22 and 26, open mould 100, then intermediate mold 140 is removed from bed die 120.After removing intermediate mold 140 as shown in Figure 3, forming groove 23 in the prefabricated component 22 down by the projection 142 of intermediate mold 140.Obviously, the position of the groove that forms on the following prefabricated component 22 and shape depend on the position of the projection that forms on the intermediate mold 140 and shape and determine.

After on following prefabricated component 22, forming groove 23, in groove 23, place boundary material 30.In following crosslinked foaming process physics or chemical bond, and boundary material 30 can be formed by one or more materials of selecting among fluent material and solid material between two prefabricated components that boundary material 30 is used for preventing to adjoin each other by interface therebetween.In addition, boundary material is unrestricted aspect its material character, as long as it can prevent physics or chemical bond between the prefabricated component.The shape of boundary material can irrespectively be constructed with the shape of groove 23, but as possible, can with the shape of groove 23 shape of structural interface material accordingly.In addition, in the present invention, under the situation that boundary material 30 is formed by solid material, the moulded product that can use arbitrary shape is as boundary material.Here, under the situation that the projection of intermediate mold is constructed as shown in Figure 9, can use by the Reference numeral among Figure 10 34 expression can be as an embodiment of the moulded product of boundary material.

Simultaneously, in the present invention, place at boundary material under the situation of groove, these boundary materials can place groove under the state that is coated by the different prefabricated components of arbitrary shape, this prefabricated component by from the identical or different material of the expanded material kind that constitutes corresponding prefabricated component among one or more materials of selecting forms and is prevented from foaming.Here, under the situation that the projection of intermediate mold is constructed as shown in Figure 9, figure 11 illustrates such an embodiment, wherein, boundary material 38 is foamed in prefabricated component 36 utilize the boundary material that is placed in the groove by the prefabricated component 36 different with following prefabricated component with last prefabricated component is provided.

After as shown in Figure 4 boundary material 30 being placed the groove 23 that prefabricated component 22 forms down, the mold 160 that will comprise prefabricated component 26 is placed on the bed die 120, so mould 100 is sealed and be heated, thereby make prefabricated component 26 and following prefabricated component 22 crosslinked foamings simultaneously.In this case, when heating sealed mould 100, interface 24 between the last prefabricated component 26 of close attachment and the following prefabricated component 22 is with the crosslinked foaming process that carries out then of the mode of gel phase each other, do not foam but the part 25 that is formed by boundary material 30 is crosslinked.Under this state, when opening mould and form when handling,, thereby in foam, form and the corresponding space of shape of boundary material because the part 25 that is formed by boundary material 30 is separated in foaming process.These spaces are in the internal structure 12 that forms in foam 10 shown in Figure 12.

Figure 13 shows such an embodiment, wherein the boundary material utilization with constitute under the different material of the expanded material of prefabricated component and the following prefabricated component situation about foaming, foam-molded part 13 is integrally formed in the foam 10.That is to say, when prefabricated component but material that foam properties to it similar different with the expanded material of following prefabricated component is as boundary material on utilizing material character or color and formation, the integrally formed material character foam-molded part different in foam with this foam.If suitably adopt this embodiment, then can make the foam that comprises foam-molded part with differing material properties, perhaps be that the appropriate section of foam is selected material character and color.

Simultaneously, be solid-state and in foam, form simultaneously under the situation of foam-molded part that the present invention also can be included in prefabricated component is carried out removing the step as the foam-molded part of boundary material after the crosslinked foaming at boundary material as present embodiment.That is to say, make the foam of form as shown in figure 13,, thereby obtain the foam shown in Figure 12 then from this suds removal foam-molded part 13.

Figure 14 shows the embodiment of the foam of making under the situation that the projection of intermediate mold is constructed as shown in Figure 9 like that.As shown in figure 14, as can be seen, can in the foam of making 10, form internal structure 14 by Reference numeral 14 expressions.Figure 15 shows the embodiment that constructs and use the foam of making under the situation of the moulded product shown in Figure 10 as boundary material in the projection of intermediate mold as shown in Figure 9 like that.As shown in figure 15, moulded product 34 is integrally formed in the foam of making as can be seen.In addition, Figure 16 shows at the projection of intermediate mold and boundary material respectively as the embodiment of Fig. 9 and the foam made under the situation of structure as shown in Figure 11.As shown in figure 16, integrally formed foam-molded part 16 and internal structure 18 in the foam of making 10 as can be seen.

Simultaneously, Fig. 5 to Fig. 7 shows the foam manufacture method of another embodiment according to the present invention.In Fig. 5 to Fig. 7, show the sectional structure chart of implementing the necessary inscape of this embodiment of the present invention respectively.In this embodiment, because therefore it can omit the description to these inscapes as mentioned above with the identical inscape shown in Fig. 1 to Fig. 4.

At first, as shown in Figure 5, the bed die 130 of the forming surface with arbitrary shape is set, then expanded material 22 is placed in the inside molding space that the forming surface by bed die 130 forms.After expanded material being placed in the bed die 130, the intermediate mold 140 that will have projection 142 is placed on the bed die 130, expanded material 26 is placed on the intermediate mold 140, the mold 170 that will have the forming surface of arbitrary shape then is placed on the intermediate mold 140, thus sealed mold 100.

After with mould 100 sealings, by suitably being heated, mould 100 make expanded

material

22 and 26 form corresponding prefabricated component and last prefabricated component down simultaneously, should go up prefabricated component and following prefabricated component and be prevented from foaming, remove intermediate mold 140 by opening mould 100 from mould 100 afterwards.When after the process molding process, removing intermediate mold 140, form groove 23 as shown in Figure 6 on the following prefabricated component 22 that in the molding space of the inside of bed die 130, forms by the projection 142 of intermediate mold 140.In groove 23, place boundary material 30.

In the time of in the groove 23 that boundary material 30 is placed on fully following prefabricated component 22, as shown in Figure 7, mould 100 is sealed in prefabricated component 26 and following prefabricated component 22 each other under the state of close attachment, then by mould 100 heating being made

prefabricated component

26 and 22 while of following prefabricated component crosslinked foaming.As mentioned above,, carry out crosslinked foaming then, then can shown in Figure 12 to 16, obtain various foam elements if suitably select intermediate mold and boundary material.

As previously discussed, although disclose preferred implementation of the present invention in order to describe, technological thought of the present invention is not limited to this explanation.

Claims

1, a kind of foam manufacture method, this method may further comprise the steps:

Setting has the bed die of arbitrary shape forming surface, order is placed intermediate mold and the mold with arbitrary shape forming surface on this bed die then, thereby with the mould sealing, this intermediate mold has the projection of at least one arbitrary shape that forms on its one or both sides;

Preventing under the condition of expanded material foaming prefabricated component and following prefabricated component on forming simultaneously by in the inside molding space of separating by described intermediate mold of described mold and described bed die, filling this expanded material;

Open mould, and remove described intermediate mold from described mold and described bed die;

In the groove that in described prefabricated component, forms by the projection of described intermediate mold, place boundary material, thereby prevent that described upward prefabricated component and described prefabricated component down are cross-linked with each other; And

Sealed mold also makes described prefabricated component and the described while crosslinked foaming of prefabricated component down gone up.

2, a kind of foam manufacture method, this method may further comprise the steps:

In the molding space of the inside of bed die, place expanded material with arbitrary shape forming surface;

Intermediate mold is set, then this intermediate mold is placed on the described bed die, this intermediate mold has the projection of at least one arbitrary shape that forms on its one or both sides;

On described intermediate mold, place expanded material, on this intermediate mold, place mold then with arbitrary shape forming surface, thus sealed mold;

Under the condition of the expanded material that is separated by the described intermediate mold foaming of placing, described expanded material is formed respectively simultaneously go up prefabricated component and following prefabricated component preventing;

Open mould and remove described intermediate mold from all the other moulds;

3, foam manufacture method according to claim 1 and 2, wherein, described boundary material is placed in the described groove under the state that is coated by the prefabricated component of different arbitrary shapes, and this prefabricated component is formed by one or more materials of selecting among the material identical or different with constituting the described material of going up prefabricated component and/or described prefabricated component down and is prevented from foaming.

4, foam manufacture method according to claim 1 and 2, wherein, described boundary material is formed by one or more materials of selecting among fluent material and the solid material.

5, foam manufacture method according to claim 4, wherein, described solid material comprises the moulded product of arbitrary shape.

6, foam manufacture method according to claim 4, wherein, when described boundary material was solid material, this method also was included in the step that the step that makes described prefabricated component crosslinked foaming removes described boundary material afterwards.

7, foam manufacture method according to claim 1 and 2, wherein, described at least one projection that forms in described intermediate mold comprises a plurality of projections, and these projections are configured to interconnect.